Harvesting Waste Energy:Bicycle Power Generation

RIT-MSD-II Design Review 5/18/122:15-2:45pm 09-4425

Winter/Spring 2011-2012P12414

Team Members• Daniel Tobin (ME)

• Aaron Sieczkarek (ME)

• Amina Purak (ISE)

• Brenda Lisitano (ME)

• Zheng (Flora) Li (EE) GUIDE: Professor Brownell

Agenda•Needs/Specs•Functional Architecture•Our Concept: Mechanical and Electrical•Final Product•Testing•Cost Worth Analysis•AMPL Program•Major Issues•Objective Evaluations•Future Considerations

Customer NeedsObjective:

To power simple personal devices using energy stored in the momentum of a bicycleNeed # Customer Needs Importance Weight

1 (Low) – 10 (High)

Need 1 The device provides power to charge a cell phone or a rechargeable battery to power LED lighting  10

Need 2 The device uses standard connectors to personal electronic devices  8

Need 3 The device resists environmental damage from dust, water, etc.  8

Need 4 The device works well on rough roads  8

Need 5 The device protects user safety  8

Need 6 The device is inexpensive to purchase, install and maintain  7

Need 7 The device is easy to maintain  6

Need 8 The device is easy to operate  6

Need 9 The device attaches to a wide variety of bicycle types  6

Need 10 The device is easy to install  5

Need 11 The device is light weight  4

Need 12 The device adds only a minimal increase in effort for the operator pedaling the bicycle, ideally none at all  4

Need 13 The device is a stylish accessory to the bicycle 3

SpecificationsSpecifications Units Ideal MarginalDC output voltage volt 4.8-5.2 4.7-5.3output current mA 250-1000 200 - 1500

Estimated biking time to generate power 1 w-hr if the device does not generate continuously hour <1.5 <3

Maximum increased effort for bicyclist % VO2 increase <3% <10%Range of bike tire sizes the device will accommodate cm 40.6-71.1 60.6-71.1

Uses standard connectors to interface with cell phone or battery charger % of 90% 60%

Size cm^3 16x16x16 28x21.6x14Number of people required to install device # of people <1 <3Number of tools required to install device # of tools <1 <3Time required for set up (each use) min <10 <20Time to train operator to use device min <10 <10Increased temperature to bicycle Parts (rim, gears, ?) Celsius Degree <5 <10

Manufactured cost ($20, per unit when manufactured in lots of 100) $ <20 <40

Installation cost $ 0 <5Resists damage from impacts/crashes IEC60529* Level 1-9 >7 >5Dustproof IEC60529* digit 1 Level 0-6 6 >5Waterproof IEC60529* digit 2 Level 0-8 >7 >4

People rating the device at 4 or above on a scale of 1-5 for aesthetically appealing % >70 >50

Functional Architecture

Our Concept: Electrical

C 81 0 u

12V DC motor C 9. 1 u

A-type USBConnector

4

1

U 4L M 3 4 0 -5

I N1

O U T2

GN

D3

0

C 71 0 u

Circuit Diagram

Our Concept: Electrical

Non-linear input test

Volta

ge(V

)

Time (s)

Our Concept: Mechanical

Electronics Box

Motor Housing

Final Product

Electronics Box

Motor Housing

Testing•All specifications tested•Either passed ideally or marginally•No tests failed•Examples of successes

▫Waterproof▫Dustproof▫Impact Test▫Voltage Test▫Aesthetic Survey

Test Results Test Ideal Value Measured Value

Ideal(I) Marginal (M) Fail (F)

Cost Analysis <$20 $15.02 IWaterproof 7 4 MDust Proof 6 6 I

Range of Bikes 60.6-71.1 (cm) 60.96-68358 (cm) MRange of Phones 90% 90% I

Rough RoadStays on and no

Damage sustained

No damage sustained M

Motor Voltage >7V >7V I

Speed to Charge <20 km/hr <20 km/hr (17 km/hr greatest) I

First Install 1 person 1 tool 1 person 0 tools I

Each Use <5min setup <10 min train

<5min setup <3 min train I

Operating Temperature Change <5 degrees C 4.9 degrees C I

Impact Resistance 15 Lbs any angle 15 Lbs any angle IOutput Current 250-1000 mA 380-892 mA I

Device Size 16x16x16 cm 16x10x12cmAesthetics 75% 4 or better 75% I

V02 <10% Statistically 0% IPhone Charging Yes Yes I

Main Usage >25% in 30 minutes 25% 30 minutes I

Output Voltage with Input Greater than 6V 5 V 5 V I

Cost AnalysisBOX ASSEMBLY MOTOR ASSEMBLY

WEIGHT

Kolpin Replacement

Straps for Rhino Grips,

Model#87010

3" Powder Coated Metal

Handrail Bracket

Westinghouse 77049 3 Stainless

Steel Beaded Chain with Connector

1" diameter, 1/4" hole

OD Washers (dan

purchased)

1/4"-20x1/2" machine

screws with nuts HOME

DEPOT

Clear Plastic Box 24 oz with lid Ollie's

Zip TiesPFP Crimp Connector

(2mm)

M-D 17'L X 1/2"W Gray Closed- Cell

Foam Window Weather

Strip

1/4"-20x3/4" machine screws HOME DEPOT

1/4"-20x1/2" machine

screws with nuts HOME

DEPOT

3/16 X .049" ALUMI TUBE

1/2" diameter extrusion

rubber roller 60A 6" length

Spring grip broom

bracket, EVERBILT

from SEARS

Rubber Dipping

material- Plasti Dip

from Menards

1.5"diameter, .5" thick aluminum billet, 6' length

mcmaster carr

2mm mcmaster car steel rod, 3 ft length

60A mcmaster rubber ,

1/4" diameter need 1/2

length

2 oz Single-Wall White

Jar

53-400 Natural

Smooth Lid with F217

Liner

Clear Aquarium

SealVoltage

Regulator10μ

Capacitor.1μ

Capacitor USB Port Bread Board Wire Quick Connect Standoffs TOTALS

DC output Voltage 3.7 9 1 1 9 1 1 1 23

DC output Current 3.7 1 1 1 1 1 1 6

Output Power 3.7 3 1 9 9 1 1 1 25

Energy Conversion Efficiency 3.4 1 1 3 1 3 9 1 9 1 1 9 1 40

Charging Rate 3.4 3 1 3 1 1 1 1 9 1 1 3 1 26

Weight 5.2 1 1 1 1 1 1 3 1 10

Size 4.1 1 1 9 1 9 21

Min Environmnt Temp 2.8 1 1 1 1 4

Max Environment Temp 2.8 1 1 1 1 4

Increased temperature through use 4 1 3 3 1 8

Water proof level 3.9 3 1 9 1 1 9 9 9 9 51

Dust proof level 4.2 3 1 9 1 1 9 1 9 9 9 52

Impats/crashes resist level 5.7 3 1 3 9 3 1 1 3 1 1 1 1 9 9 46

Wire strength 4.4 9 9

Increased opperator effort 5.5 9 1 1 11

Device Connector 5.7 1 3 1 1 1 7

Installation Cost 4.2 1 1 1 3

Installation Time 5.4 1 1 1 1 4

Installation People 4.7 1 1 2

Instalation Tools 4.7 1 9 1 9 20

Trainning Time(opparating) 4.4 1 1 1 1 1 1 6

Appearence 4.1 3 1 1 1 1 9 1 3 3 1 1 1 26

Manufactoring cost 6.3 1 1 1 1 1 9 1 1 1 1 1 1 1 9 1 3 1 1 1 3 1 1 1 1 1 1 1 1 48

RAW SCORE 0.684 0.337 0.2 0.404 0.779 2.643 0.291 0.234 0.592 0.201 0.201 0.287 0.119 1.392 1.028 0.569 0.759 0.665 2.293 1.346 0.918 0.834 0.171 0.171 1.341 0.242 0.678 0.471 0.242 20.092

Relative WORTH 3.40% 1.68% 1.00% 2.01% 3.88% 13.15% 1.45% 1.16% 2.95% 1.00% 1.00% 1.43% 0.59% 6.93% 5.12% 2.83% 3.78% 3.31% 11.41% 6.70% 4.57% 4.15% 0.85% 0.85% 6.67% 1.20% 3.37% 2.34% 1.20% 100.00%

ACTUAL COST 2 0.9 0.2 1.12 3.136 0.378 1 0.48 0.087647 0.196 0.196 0.448333 0.976 0.99 0.688 0.456286 0.198 0.402556 0.22 0.17 0.087647 0.4 0.62 0.62 1 0.48 0.05 1.495 0.01 $19.01

RELATIVE COST 10.53% 4.74% 1.05% 5.89% 16.51% 1.99% 5.26% 2.53% 0.46% 1.03% 1.03% 2.36% 5.14% 5.21% 3.62% 2.40% 1.04% 2.12% 1.16% 0.89% 0.46% 2.11% 3.26% 3.26% 5.26% 2.53% 0.26% 7.87% 0.05% 100.03%

BOX ASSEMBLY

WEIGHT

Kolpin Replacement Straps for Rhino

Grips, Model#87010

3" Powder Coated Metal

Handrail Bracket

Westinghouse 77049 3 Stainless

Steel Beaded Chain with Connector

1" diameter, 1/4" hole OD Washers (dan

purchased)

1/4"-20x1/2" machine

screws with nuts HOME

DEPOT

Clear Plastic Box 24 oz with lid Ollie's

Zip Ties

DC output Voltage 3.7 DC output Current 3.7 Output Power 3.7 Energy Conversion Efficiency 3.4 Charging Rate 3.4 Weight 5.2 1 1 1 1 Size 4.1 1 1 9 Min Environmnt Temp 2.8 Max Environment Temp 2.8 Increased temperature through use 4 Water proof level 3.9 3 1 9 Dust proof level 4.2 3 1 9 Impats/crashes resist level 5.7 3 1 3 9 3Wire strength 4.4 Increased opperator effort 5.5 Device Connector 5.7 1Installation Cost 4.2 1 1 Installation Time 5.4 1 1 Installation People 4.7 1 Instalation Tools 4.7 1 9 Trainning Time(opparating) 4.4 1 1 1 1 Appearence 4.1 3 1 1 1 1 9 Manufactoring cost 6.3 1 1 1 1 1 9 1

RAW SCORE 0.684 0.337 0.2 0.404 0.779 2.643 0.291Relative WORTH 3.40% 1.68% 1.00% 2.01% 3.88% 13.15% 1.45%

ACTUAL COST 2 0.9 0.2 1.12 3.136 0.378 1RELATIVE COST 10.53% 4.74% 1.05% 5.89% 16.51% 1.99% 5.26%

Cost Analysis

0.00% 2.00% 4.00% 6.00% 8.00% 10.00% 12.00% 14.00% 16.00% 18.00% 20.00%0.00%

2.00%

4.00%

6.00%

8.00%

10.00%

12.00%

14.00%

16.00%

18.00%

20.00%

Cost-Worth Diagram(Based on "Total Part Cost" as divisor)

Relative Worth

Rel

ativ

e C

ost

Line Balancing Program#SETSset T; #tasksset N; #stationsset PreT{T}; #subset of precedence

#PARAMETERSparam c; #Cycle time in hours (p=10, s=7.5; c=1.5hrs)param d{j in T}; #task durationparam b{j in T, k in N}; #cost of doing task "j" in station "k"

#VARIABLESvar X {j in T, k in N} binary; #1, if task "j" is assigned to station "k", 0, otherwise

#OBJECTIVE FUNCTIONminimize Stations: sum{j in T, k in N} b[j,k]*X[j,k];

#CONSTRAINTSsubject to TaskAssignment {j in T}: sum{k in N} X[j,k] = 1;subject to CompletionTime {k in N}: sum{j in T} d[j]*X[j,k] <= c;subject to Precedence {j in T, k in N, i in PreT[j]:i>0}: X[j,k] <= sum{f in 1..k}X[i,f];

Line Balancing ResultsCycle Time 10 30 60

Stations Needed 8 3 2

Finished Product

Electronics

Housing

Mechanical BOX

Electrical CB

Motor Housing

Electrical Motor

Mechanical Motor

ndMarketDemaimeAvailableTCycleTime

Feasible results will be attained for Cycle Times 9 minutes or greater.

Shorter Cycle Times will require a further break down of manufacturing processing times.

Life Cycle Assessment

LCA Graphs – ENERGY & CO2 Summary

Major Issues

•Concept Choice in MSD I

•Initially ordering parts at a low cost

•Material selection

Objective Evaluation

•Final product meets customer requirements as a proven, robust, functional prototype. Project is on time and under budget.

•Several improvements could be made:▫Reduced number of parts▫Decreased complexity of design▫Increased grip of spring clip design ▫Aesthetic appeal

Future Considerations•A better phone container could be utilized

that is completely waterproof.•Decrease number of tools required to

build device as to be easily constructed in Haiti

•Utilize a specialized motor•Contact Industrial Design Department to

find out if any students wish to work on the project as well.

•Systems modeling of the motor output and circuitry with a dynamic model.

We’re Out!